Laminates with micro-texture

ABSTRACT

A laminate with micro-texture having attachment lines oriented in a primary direction and mechanically activated in the primary direction.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. provisional patentapplication 61/226,412 filed Jul. 17, 2009, the substance of which ishereby incorporated by reference.

FIELD

In general, embodiments of the present disclosure relate to laminates.In particular, embodiments of the present disclosure relate to activatedlaminates with micro-texture for use with absorbent articles.

BACKGROUND

Absorbent articles can absorb liquid bodily exudates such as sweat,blood, urine, menses, etc. An absorbent article can include elasticmaterials. Unfortunately, some elastic materials may have a roughplastic appearance or feel. Some integral elastic materials may notappear finished and garment-like. And some elastic materials tend to usematerials inefficiently. Also some elastic materials may not adequatelyconform the article to a wearer's body. Absorbent articles with suchelastic materials may look unattractive, cost more, and perform poorly.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A illustrates a front outside perspective view of afront-fastenable wearable absorbent article formed for wearing, whereinthe article includes laminates with micro-texture of the presentdisclosure.

FIG. 1B illustrates a back outside perspective view of the article ofFIG. 1A.

FIG. 2A illustrates a front outside perspective view of a pant-typewearable absorbent article formed for wearing, wherein the wherein thearticle includes laminates with micro-texture of the present disclosure.

FIG. 2B illustrates a back outside perspective view of the article ofFIG. 2A.

FIG. 3A illustrates a top view of a two-layer intermediate laminate ofthe present disclosure, before activation.

FIG. 3B illustrates a top view of the laminate of FIG. 3A, afteractivation, in a flat state.

FIG. 3C illustrates a side view of the activated laminate of FIG. 3B.

FIG. 3D illustrates an end view of the activated laminate of FIG. 3B.

FIG. 3E illustrates a top view of the laminate of FIG. 3B, in acontracted state with micro-texture shown.

FIG. 3F illustrates a side view of the activated laminate withmicro-texture of FIG. 3E.

FIG. 3G illustrates an enlarged end view of the activated laminate withmicro-texture of FIG. 3E.

FIG. 4A illustrates a top view of a three-layer laminate of the presentdisclosure, after activation, in a flat state.

FIG. 4B illustrates a side view of the activated laminate of FIG. 4A.

FIG. 4C illustrates an end view of the activated laminate of FIG. 4A.

FIG. 4D illustrates a top view of the laminate of FIG. 4A, in acontracted state with micro-texture shown.

FIG. 4E illustrates a side view of the activated laminate withmicro-texture of FIG. 4D.

FIG. 4F illustrates an enlarged end view of the activated laminate withmicro-texture of FIG. 4D.

FIG. 5A illustrates a top view of an alternate embodiment of athree-layer laminate of the present disclosure, after activation, in aflat state.

FIG. 5B illustrates a side view of the activated laminate of FIG. 5A.

FIG. 5C illustrates an end view of the activated laminate of FIG. 5A.

FIG. 6A illustrates a top view of another alternate embodiment of athree-layer laminate of the present disclosure, after activation, in aflat state.

FIG. 6B illustrates a side view of the activated laminate of FIG. 6A.

FIG. 6C illustrates an end view of the activated laminate of FIG. 6A.

FIG. 7A illustrates a top view of an alternate embodiment of a two-layerlaminate of the present disclosure, after activation, in a flat state.

FIG. 7B illustrates a side view of the activated laminate of FIG. 7A.

FIG. 7C illustrates an end view of the activated laminate of FIG. 7A.

FIG. 8A illustrates a top view of a laminate of the present disclosure,with curved attachment lines, before activation.

FIG. 8B illustrates a top view of the laminate of FIG. 8A, afteractivation, with micro-texture.

FIG. 9A illustrates a top view of a laminate of the present disclosure,with oscillating attachment lines, before activation.

FIG. 9B illustrates a top view of the laminate of FIG. 9A, afteractivation, with micro-texture.

FIG. 10A illustrates a top view of a laminate of the present disclosure,with attachment lines comprising a series of dashes, before activation.

FIG. 10B illustrates a top view of the laminate of FIG. 10A, afteractivation, with micro-texture.

FIG. 11A illustrates a top view of a laminate of the present disclosure,with attachment lines comprising a series of dots, before activation.

FIG. 11B illustrates a top view of the laminate of FIG. 11A, afteractivation, with micro-texture.

FIG. 12A illustrates a top view of a laminate of the present disclosure,with attachment lines having a single open spiral pattern, beforeactivation.

FIG. 12B illustrates a top view of the laminate of FIG. 12A, afteractivation, with micro-texture.

FIG. 13A illustrates a top view of a laminate of the present disclosure,with attachment lines having a single tight spiral pattern, beforeactivation.

FIG. 13B illustrates a top view of the laminate of FIG. 13A, afteractivation, with micro-texture.

FIG. 14A illustrates a top view of a laminate of the present disclosure,with attachment lines having a dual tight spiral pattern, beforeactivation.

FIG. 14B illustrates a top view of the laminate of FIG. 14A, afteractivation, with micro-texture.

FIG. 15A illustrates a top view of a laminate of the present disclosure,with randomly oriented attachment lines, before activation.

FIG. 15B illustrates a top view of the laminate of FIG. 15A, afteractivation, with micro-texture.

FIG. 16A is a microscopic photograph of an outer edge of an activatedlaminate with micro-texture of the present disclosure, in a contractedstate.

FIG. 16B is a microscopic photograph of a cross-section of an activatedlaminate with micro-texture of the present disclosure, in a contractedstate.

FIG. 17 is a graph illustrating number of shirrs per centimeter versusattachment line spacing for exemplary embodiments of an activatedlaminate with micro-texture of the present disclosure.

FIG. 18 is a graph illustrating shirr height versus attachment linespacing for exemplary embodiments of an activated laminate withmicro-texture of the present disclosure.

DETAILED DESCRIPTION

The embodiments of laminate with micro-texture of the present disclosurecan be used with all kinds of absorbent articles and disposablegarments. An absorbent article can absorb liquid bodily exudates such assweat, blood, urine, menses, etc. An absorbent article can be a productor a material. Examples of absorbent articles include products and/ormaterials for sanitary protection, hygienic use, and/or wound care.

Some absorbent articles are disposable. A disposable absorbent articleis configured to be partly or wholly disposed of after a single use. Adisposable absorbent article is configured such that the soiled article,or a soiled portion of the article, is not intended to be restored andreused (e.g., not intended to be laundered). Examples of disposableabsorbent articles include wound care products, such as bandages anddressings, as well as feminine care products, such as pads and liners.Disposable absorbent articles can use embodiments of the presentdisclosure.

Some absorbent articles are wearable. A wearable absorbent article isconfigured to be worn on or around a body of a wearer. Wearableabsorbent articles can also be disposable. Examples of disposablewearable absorbent articles include disposable diapers and disposableincontinence undergarments. A disposable wearable absorbent article canreceive and contain bodily exudates while being worn by a wearer. Insome embodiments, a disposable wearable absorbent article can include atopsheet, an absorbent core, an outer cover, a waist opening, and legopenings. Disposable wearable absorbent articles can use embodiments ofthe present disclosure.

The embodiments of laminates with micro-texture of the presentdisclosure can be used in a front waistband, back waistband, leg band,ear, side panel, topsheet, anchoring band, extensible outer cover,and/or other suitable portions of a wearable absorbent article, asdescribed herein. Such laminates can be attached to a wearable absorbentarticle as sheets, discrete pieces, or continuous bands, on the wearerside, on the garment side, or interposed between layers of the article(e.g. integral). The laminate can be attached in any manner known in theart, such as adhesive attachment, pressure bonding, thermal bonding,ultrasonic bonding, and the like, or combinations of any of these.

The figures of the present disclosure are intended to illustrateelements, their parts, and their relationships, as described in thespecification; the figures are not intended to illustrate any particularrelative or absolute size or dimension, unless otherwise stated in thetext.

FIG. 1A illustrates a front outside perspective view of afront-fastenable wearable absorbent article 100 formed for wearing. Thearticle 100 has a front 101 and a back 105. The article includes a frontwaistband 120-1, legbands 120-3, a back waistband 120-5, and side ears120-6. Any of the front waistband 120-1, legbands 120-3, back waistband120-5, and side ears 120-6, or a portion thereof, can be configured toinclude or be formed from any of the embodiments of the laminates withmicro-texture of the present disclosure.

While the present disclosure refers to front-fastenable absorbentarticles, the present disclosure also contemplates alternate embodimentsof absorbent articles using laminates, as described herein, wherein theabsorbent articles are rear-fastenable or side fastenable. Thus, eachembodiment of an absorbent article of the present disclosure that isdescribed as front-fastenable can also be configured to be rearfastenable or side-fastenable, as will be understood by one of ordinaryskill in the art.

FIG. 1B illustrates a back outside perspective view of the article ofFIG. 1A.

FIG. 2A illustrates a back outside perspective view of a pant-typewearable absorbent article 200 formed for wearing. The article 200 has afront 201 and a back 205. The article includes a front waistband 220-1,legbands 220-3, a back waistband 220-5, and side panels 220-8. Any ofthe front waistband 220-1, legbands 220-3, back waistband 220-5, andside panels 220-8 can be configured to include or be formed from any ofthe embodiments of the laminates with micro-texture of the presentdisclosure.

Throughout the present disclosure, a reference to a pant-type wearableabsorbent article refers to an article with sufficient stretch to enableit to be readily pulled over a wearer's hips and buttocks while thewaist and leg openings are formed. A pant-type wearable absorbentarticle can refer to an embodiment that is side-fastenable, to anembodiment that is front-fastenable, to an embodiment that isrear-fastenable, or to an embodiment without fasteners. A reference to apant-type wearable absorbent article can also refer to an article withpreformed waist and/or leg openings or to an embodiment that is notpreformed. Thus, each embodiment of an absorbent article of the presentdisclosure that is described as pant-type can be configured in any ofthese ways, as will be understood by one of ordinary skill in the art.

FIG. 2B illustrates a back outside perspective view of the article ofFIG. 2A.

FIG. 3A illustrates a top view of an intermediate laminate 321 beforebeing mechanically activated by incremental stretching. For reference,the intermediate laminate 321 includes a primary direction 370 and asecondary direction 380. The secondary direction 380 is perpendicular tothe primary direction 370.

The intermediate laminate 321 has a first layer 330-1 and a second layer330-2. The first layer 330-1 is disposed subjacent to the second layer330-2. The intermediate laminate 321 also includes a plurality of firstattachment lines 340. The first attachment lines 340 include a firstline 340-1, a second line 340-2, and a third line 340-3. The firstattachment lines 340 are disposed between the first layer 330-1 and thesecond layer 330-2. The second layer 330-2 is illustrated assemi-transparent, so the first attachment lines 340 are visible throughthe second layer 330-2. For purposes of illustration, a portion of thesecond layer 330-2 and a portion of the third line 340-3 are shownbroken away.

The intermediate laminate 321 is in the form of a sheet-like band andhas an overall length 372 in a longitudinal direction, which is parallelwith the primary direction 370, and an overall initial width 382 in thesecondary direction 380. In the embodiment of FIG. 3A, the overalllength 372 is much greater than the overall initial width 382, resultingin the intermediate laminate 321 with an overall rectangular shape;however this is not required and the intermediate laminate 321 can beconfigured in various other shapes, e.g., via curving the laminate on anarticle or folding or cutting it to shape it.

In various embodiments, the overall initial width 382 can have variousdimensions. For example, the intermediate laminate 321 can have anoverall width 382 that is less than or equal to 50 millimeters, lessthan or equal to 40 millimeters, less than or equal to 30 millimeters,less than or equal to 20 millimeters, less than or equal to 15millimeters, less than or equal to 10 millimeters, or less than or equalto any integer value from 0 to 50 millimeters.

In an alternate embodiment, the intermediate laminate 321 can beconfigured such that the primary direction 370 is angled with respect tothe longitudinal direction of the intermediate laminate 321. Forexample, the primary direction 370 can be angled within 45 degrees, 30degrees, 15 degrees, or substantially parallel with the longitudinaldirection, or at any other angle.

The first layer 330-1 has, in the primary direction 370, a firstextensibility and a first elasticity with a first set. The second layer330-2 has, in the primary direction 370, a second extensibility and asecond elasticity with a second set.

As used herein, the term “extensibility” refers to the ability of amaterial to elongate to a given percentage, without substantial ruptureor breakage. Micro-sized rupture or breakage of a material is notconsidered substantial rupture or breakage. However, macro-sizedruptures through the structure (e.g. one or more large tears such astears greater than about 5 millimeters in any direction, or breakinginto two or more pieces, or resulting in significant structuraldegradation which may render the material unusable for its intendedpurpose) are considered substantial ruptures or breakage.

In various embodiments, the first layer 330-1 can have a firstextensibility that is greater than or equal to 50%, greater than orequal to 100%, greater than or equal to 200%, greater than or equal to350%, greater than or equal to 500%, or any integer value for percentfrom 0% to 500%. In some embodiments, the second layer 330-2 can have asecond extensibility that is greater than or equal to 50%, greater thanor equal to 100%, greater than or equal to 200%, greater than or equalto 350%, greater than or equal to 500%, or greater than any integervalue for percent from 0% to 500%.

In the embodiment of FIG. 3A, the second set of the second layer 330-2is greater than the first set of the first layer 330-1. In variousembodiments, the second layer 330-2 can have a second set that isgreater than or equal to 50%, greater than or equal to 60%, greater thanor equal to 70%, greater than or equal to 80%, greater than or equal to90%, equal to about 100%, or greater than any integer value for percentfrom 50% to 100%, when the set is measured by using the Hysteresis Testmethod, as described herein.

The first layer 330-1 and/or the second layer 330-2 can include or beformed by one or more of various kinds of materials, such as nonwovens,films, foams, coextruded skin/monolayers, laminates, and combinationsthereof. The first layer 330-1 and/or the second layer 330-2 can includeor be formed by one or more sheets of material. In a first exemplaryembodiment, the first layer 330-1 can be a sheet of film having elasticproperties and the second layer 330-2 can be a sheet of film havingplastic properties. In a second exemplary embodiment, the first layer330-1 can be a sheet of film having elastic properties and the secondlayer 330-2 can be a sheet of nonwoven laminated to a film havingplastic properties. In various embodiments, the outer surface of thefirst layer 330-1 and/or the second layer 330-2 can be treated byvarious methods to improve its surface properties, such as softness.

Additionally, the first layer 330-1 can include or be formed by one ormore bands of material, strands of material, and combinations thereof.The first layer 330-1 can include or be formed by one or morecompositions of materials, such as thermoplastic elastomers, styrenicblock copolymers, styrene ethylbutylene styrene, styrene ethylenepropylene styrene, styrene ethylene ethylene propylene styrene, styrenebutadiene styrene, styrene isoprene styrene, polyolefin elastomers,polyurethanes, polyesters, rubbers, Vistamaxx™ from Exxon-Mobil,Versify™ from Dow, Adflex™ from LyondellBasell, and combinationsthereof. The second layer 330-2 can include or be formed by one or morecompositions of materials, such as polyethylenes (e.g. LDPEs andLLDPEs), polypropylenes, copolymers, polyolefins, filled polyolefins,polyesters, and combinations thereof. The first layer 330-1 and/or thesecond layer 330-2 can have a basis weight that is less than or equal to500 grams per square meter (gsm), less than or equal to 200 gsm, lessthan or equal to 100 gsm, or any integer value for gsm within any ofthese ranges.

Part, parts, substantially all, or all of the first layer 330-1 and/orthe second layer 330-2 can be liquid impermeable or liquid permeable.The first layer 330-1 and/or the second layer 330-2 can be vaporimpermeable or vapor permeable. In various embodiments, either or bothof the layers can be permeable by their construction, or renderedpermeable by aperturing.

The first layer 330-1 is attached to the second layer 330-2 by a firstattachment area. In various embodiments, greater than 50%, at least 60%,at least 70%, at least 80%, at least 90%, substantially all, or all ofthe first attachment area is formed by the first attachment lines 340.Also in various embodiments, the first attachment lines 340 can form anyinteger value for percent from 50% to 100% of the first attachment area.

Each of the first attachment lines 340 is oriented in a direction oforientation that is parallel with each other, however, in someembodiments, this is not required. Each of the first attachment lines340 is also oriented in a direction of orientation that is parallel withthe primary direction 370, however, in some embodiments, this is alsonot required.

Each of the first attachment lines 340 is a continuous straight line.However, in various embodiments, part, or parts, or substantially all,or all of one or more of the first attachment lines 340 can include acontinuous line, or a substantially continuous line, or a discontinuousline, or a series of line segments, or a series of dashes, a series ofdots, or combinations of any of these. Also, in various embodiments,part, or parts, or substantially all, or all of one or more of the firstattachment lines 340 can be curved, segmented, or patterned. Any of thefirst attachment lines 340 can be any kind of attachment, such as a lineof embossment, a line of thermal bonding, a line of ultrasonic bonding,a line of adhesive, etc. For example, a line of adhesive could be formedfrom adhesives H2031, H2861, or H2988F available from Bostik, Inc. ofWauwatosa, Wis., or from adhesive 526 available from National Adhesivesof Bridgewater, N.J. Without wishing to be bound by the theory, it isbelieved that the adhesive should be sufficiently flowable to survive amechanical activation process while still adhering to the layers towhich it is attached.

The first layer 330-1 is attached to the second layer 330-2 by anattachment with an overall peel strength. In various embodiments,greater than 50%, at least 60%, at least 70%, at least 80%, at least90%, substantially all, or all of the overall peel strength is providedby the first attachment lines 340. Also in various embodiments, thefirst attachment lines 340 can provide any integer value for percentfrom 50% to 100% of the overall peel strength of the attachment. As anexample, while the first layer 330-1 may be continuously attached to thesecond layer 330-2, greater than 50%, at least 60%, at least 70%, atleast 80%, at least 90%, substantially all, or all of the overall peelstrength can be provided by the first attachment lines 340, with thebalance of the overall peel strength provided by areas outside of thefirst attachment lines 340.

In the embodiment of FIG. 3A, the first layer 330-1 and the second layer330-2 are each relaxed when they are attached to each other. However, invarious embodiments, the first layer 330-1 can be prestrained to variousrelative prestrains as it is attached to the second layer 330-2. Asexamples, the first layer 330-1 can be attached to the second layer330-2 at a relative prestrain that is greater than or equal to 500%,greater than or equal to 350%, greater than or equal to 200%, greaterthan or equal to 100%, greater than or equal to 50%, or greater than orequal to any integer value for percent from 50% to 500%. As furtherexamples, the first layer 330-1 can be attached to the second layer330-2 at a relative prestrain that is less than or equal to 20%, lessthan or equal to 15%, less than or equal to 10%, less than or equal to5%, about zero, equal to zero, or less than or equal to any integervalue for percent from 20% to 0%.

In an exemplary embodiment, the second layer 330-2 can be a sheet offilm with plastic properties that is attached to a first side the firstlayer 330-1, as described above, while the first layer 330-1 can be alaminate with overall elastic properties, wherein the laminate is formedfrom a sheet of film with elastic properties on the first side and asheet of film with plastic properties on the opposite side. Invariations of this exemplary embodiment, the elastic film can compriseat least 50%, at least 60%, at least 70%, at least 80%, or more of thetotal thickness of the first layer 330-1. In this exemplary embodiment,the plastic properties on the opposite side of the first layer 330-1 canhelp balance out the effects of the plastic properties of the secondlayer 330-2, resulting in an intermediate laminate 321 that tends to lieflat.

Once the first layer 330-1 is attached to the second layer 330-2, asdescribed above, the intermediate laminate 321 is formed. Theintermediate laminate can then be mechanically activated to form theactivated laminate 322 of FIG. 3B.

FIG. 3B illustrates a top view of an activated laminate 322, which isthe intermediate laminate 321 after being mechanically activated byincremental stretching. As a result, in the activated laminate 322, thesecond layer 330-2 has been set. In FIG. 3A, the activated laminate 321is illustrated in an extended state, as if pulled flat to remove allcontraction.

The activation can be accomplished in various ways, such as by extendingthe intermediate laminate 321 in the primary direction 370, stretchingthe intermediate laminate 321 between several pairs of nip rolls witheach pair running at a higher speed compared to the previous one,incrementally stretching the intermediate laminate 321, or otheractivation techniques, such as ring-rolling. The activation process canbe applied to the intermediate laminate 321 in a relaxed state or undera process tension. It is contemplated that the activation process can beapplied to the intermediate laminate 321 before it is attached to anarticle or after it is attached to the article. In various embodiments,the activation can be accomplished using a profiled activation process,such as those described in US patent application entitled “Process forActivating a Web”, filed Nov. 19, 2007 and published as US publication20090127742. In various embodiments, the activation can be applied in adirection that is angled with respect to the primary direction. Forexample, the actication can be applied in a direction that is at anangle of 45 degrees, 30 degrees, or 15 degrees with respect to theprimary direction, or at any other angle. It is contemplated that theactivation process can be applied at various temperatures.

In the embodiment of FIG. 3A, the activated laminate 322 is illustratedas including a plurality of tooth marks 362 from an intermeshing ofteeth in an activation process. As an example, the inelastic extensioncan be accomplished with intermeshing teeth having 0.100″ pitch, with a5.27 millimeter depth of engagement. In various embodiments, during theactivation process, the intermediate laminate 321 can be extended, inthe primary direction 370, at least 20%, at least 50%, at least 100%, atleast 150%, at least 200%, at least 250%, at least 300%, at least 350%,at least 400%, at least 450%, at least 500%, or any integer value forpercent from 50% to 500%. The activated laminate 322 may or may not beactivated in the secondary direction 380, or any other direction, beforeor after attachment to an article. The activated laminate 321 has anoverall extended length 374, measured in the primary direction 370, andan overall extended width 384, measured in the secondary direction 380.The overall extended width 384 is similar to the overall initial width382, or slightly less due to due to neckdown and/or plastic deformationfrom the activation process.

The activated laminate 322 has, in the primary direction 370, a laminateextensibility. In various embodiments, the activated laminate 322 canhave a laminate extensibility that is greater than or equal to 10%,greater than or equal to 20%, greater than or equal to 35%, greater thanor equal to 50%, greater than or equal to 100%, greater than or equal to200%, greater than or equal to 350%, greater than or equal to 500%, orany integer value for percent from 0% to 500%.

The activated laminate 322 has, in the primary direction 370, a laminateset. In various embodiments, the activated laminate 322 can have alaminate set that is less than or equal to 50%, less than or equal to35%, less than or equal to 20%, less than or equal to 15%, less than orequal to 10%, less than or equal to 5%, or less than or equal to anyinteger value for percent from 50% to 0%, when the set is measured byusing the Hysteresis Test method, as described herein.

FIG. 3C illustrates a side view of the activated laminate 322 of FIG.3B. The activated laminate 322 has an overall thickness 394 in theextended state. The overall thickness 394 is measured in a tertiarydirection that is perpendicular to the primary direction 370 andperpendicular to the secondary direction 380.

FIG. 3D illustrates an end view of the activated laminate 322 of FIG.3B. While the activated laminate 322 includes three first attachmentlines 340, in various embodiments, the activated laminate 322 caninclude one, two, three, four, five, six, seven, eight, nine, ten, ormore attachment lines.

The first line 340-1 is spaced apart from the left edge of the activatedlaminate 322 by a first distance 384-1, measured in the secondarydirection 380 from the left edge to the center of the first line 340-1.The second line 340-2 is spaced apart from the first line 340-1 by asecond distance 384-2, measured in the secondary direction 380 from thecenter of the first line 340-1 to the center of the second line 340-2.The third line 340-3 is spaced apart from the second line 340-2 by athird distance 384-3, measured in the secondary direction 380 from thecenter of the second line 340-2 to the center of the third line 340-3.The third line 340-3 is also spaced apart from the right edge of theactivated laminate 322 by a fourth distance 384-4, measured in thesecondary direction 380 from the center of the third line 340-3 to theright edge.

In various embodiments, the first attachment lines 340 can havesubstantially uniform or uniform spacing. For example, in the activatedlaminate 322, the second distance 384-2 and the third distance 384-3 canbe substantially equal or equal.

Adjacent lines in the first attachment lines 340 can be spaced apart byvarious distances. As examples, adjacent lines in the first attachmentlines 340 can be spaced apart by a distance that is greater than orequal to 0.5 millimeters, greater than or equal to one millimeter,greater than or equal to two millimeters, greater than or equal to fourmillimeters, greater than or equal to six millimeters, greater than orequal to eight millimeters, greater than or equal to ten millimeters,greater than or equal to twelve millimeters, greater than or equal tofifteen millimeters, greater than or equal to twenty millimeters,greater than or equal to twenty five millimeters, or greater than orequal to thirty millimeters.

Any of the lines in the first attachment lines 340 can have various linewidths, measured across the cross-section of the line, in the secondarydirection 380. As examples, an attachment line can have a line widththat is less than or equal to five millimeters, less than or equal tothree and a half millimeters, less than or equal to two millimeters,less than or equal to one millimeter, less than or equal to 0.8millimeters, less than or equal to 0.6 millimeters, less than or equalto 0.4 millimeters, less than or equal to 0.2 millimeters, or less thanor equal to 0.1 millimeters.

FIG. 3E illustrates a top view of the activated laminate 322 of FIG. 3Bwith micro-texture, in a contracted state. The activated laminate 322has an overall extended length 376, measured in the primary direction370, and an overall contracted width 386, measured in the secondarydirection 380. The overall contracted width 386 is similar to theoverall extended width 384, or slightly less due to contraction of theactivated laminate 322. The second layer 330-2 includes a plurality ofshirrs 332, which form the micro-texture. The shirrs 332 are theelongated gathers of the material of the second layer 330-2 that areformed when, after the activation process, the first layer 330-1contracts the laminate 332 in the primary direction 370.

In the embodiment of FIG. 3E, all of the shirrs 332 are parallel witheach other and with the secondary direction 380. That is, the shirrs 332tend to form substantially regular peaks and valleys, wherein theshirrs' 332 direction of elongation extends along in the secondarydirection 380. In various embodiments, the shirrs can be oriented within45 degrees of the secondary direction 380, within 30 degrees of thesecondary direction 380, within 15 degrees of the secondary direction380, or substantially parallel with the secondary direction 380.

In various embodiments, the shirrs 332 can be configured to have variousspacings. As examples, the shirrs 332 can be spaced such that there areat least two, at least four, at least eight, at least twelve, at leastsixteen, at least twenty, at least twenty five, or at least thirtyshirrs per centimeter in the primary direction 370. The spacing of theshirrs 332 may or may not be uniform throughout the activated laminate322 with micro-texture.

The shirrs 332 have an overall height 392, measured in the tertiarydirection 390. As examples, the shirrs 332 can be configured to have anoverall height 392 that is less than or about equal to 0.02 millimeters,less than or about equal to 0.04 millimeters, less than or about equalto 0.06 millimeters, less than or about equal to 0.08 millimeters, lessthan or about equal to 0.1 millimeters, less than or about equal to 0.12millimeters, less than or about equal to 0.15 millimeters, less than orabout equal to 0.2 millimeters, less than or about equal to 0.25millimeters, less than or about equal to 0.30 millimeters, less than orabout equal to 0.40 millimeters, or less than or about equal to 0.50millimeters.

FIG. 3F illustrates a side view of the activated laminate 322 withmicro-texture of FIG. 3E.

FIG. 3G illustrates an enlarged end view of the activated laminate 322with micro-texture of FIG. 3E. The activated laminate 322 includes afirst distance 386-1, a second distance 386-2, a third distance 386-3,and a fourth distance 386-4, which are respectively the same asdistances 384-1, 384-2, 384-3, and 384-4, or slightly less due toneckdown and/or plastic deformation from the activation process. Thefirst layer 330-1 includes a plurality of corrugations 334, wherein thefirst layer 330-1 rises up to each attachment line in the firstattachment lines 340 and drops down between the attachment lines. Thecorrugations 334 are the wave-like ridges and hollows of the material ofthe first layer 330-1 that are formed when, after the activationprocess, the overall width of the second layer 330-2 is reduced as thesecond layer 330-2 forms the shirrs 332.

In the embodiment of FIG. 3G, all of the corrugations 334 are parallelwith each other and with the primary direction 370. That is, thecorrugations 334 tend to form substantially regular ridges and hollowsthat extend along in the primary direction 370. In various embodiments,the corrugations can be oriented within 45 degrees of the primarydirection 370, within 30 degrees of the primary direction 370, within 15degrees of the primary direction 370, or substantially parallel with theprimary direction 370.

The corrugations 334 have an overall height 391, measured in thetertiary direction 390. As examples, the corrugations 334 can beconfigured to have an overall height 391 that is less than or aboutequal to 0.2 millimeters, less than or about equal to 0.4 millimeters,less than or about equal to 0.6 millimeters, less than or about equal to0.8 millimeters, less than or about equal to 1.0 millimeters, less thanor about equal to 1.5 millimeters, less than or about equal to 2.0millimeters, or less than or about equal to 3.0 millimeters. Thecorrugations 334 add caliper and softness to the laminate 322.

FIG. 4A illustrates a top view of a three-layer laminate 422 of thepresent disclosure, after activation, in a flat state. The activatedlaminate 422 is the same as the activated laminate 322, with likenumbered elements configured in the same way, except as described below.The intermediate laminate, from which the activated laminate 422 isformed, is not illustrated, although, based on the embodiments of FIGS.3A-3F, its structure and form will be understood by one of ordinaryskill in the art.

In addition to the first layer 430-1 and the second layer 430-2, theactivated laminate 422 includes a third layer 430-3. The third layer430-3 is configured in the same way as the second layer 430-2, with likenumbered elements configured in the same way, except as described below.The third layer 430-3 is attached to the first layer 430-1. For purposesof illustration, a portion of the second layer 430-2 and a portion ofthe first layer 430-1 are shown broken away.

The third layer 430-3 is attached to the first layer 430-1 by a secondattachment area that includes second attachment lines 450. The secondattachment lines 450 include a fourth line 450-4 and a fifth line 450-5.The second attachment area is configured in the same way as the firstattachment area, except that the second attachment lines 450 arepositioned differently than the first attachment lines 440. The thirdlayer 430-3 has an overall height 493 that is configured in the same wayas the overall height 492 of the second layer 430-2.

FIG. 4B illustrates a side view of the activated laminate 422 of FIG.4A.

FIG. 4C illustrates an end view of the activated laminate of FIG. 4A.The fourth line 450-4 is spaced apart from the left edge of theactivated laminate 422 by a fifth distance 484-5, measured in thesecondary direction 480 from the left edge to the center of the fourthline 450-4. The fifth line 450-5 is spaced apart from the fourth line450-4 by a sixth distance 484-6, measured in the secondary direction 480from the center of the fourth line 450-4 to the center of the fifth line450-5. The fifth line 450-5 is also spaced apart from the right edge ofthe activated laminate 422 by a seventh distance 484-7, measured in thesecondary direction 480 from the center of the fifth line 450-5 to theright edge. In the embodiment of FIG. 4C, the fourth line 450-4 ispositioned intermediate the first line 440-1 and the second line 440-2,while the fifth line 450-5 is positioned intermediate the second line440-2 and the third line 440-3. In some embodiments, the secondattachment lines 450 can be positioned halfway between the firstattachment lines 440.

In various embodiments, the second attachment lines 450 can havesubstantially uniform or uniform spacing. The second attachment lines450 can be spaced apart from each other by the same distances as thefirst attachment lines 440 are spaced apart or by different distances.

FIG. 4D illustrates a top view of the laminate 422 of FIG. 4A withmicro-texture, in a contracted state.

FIG. 4E illustrates a side view of the activated laminate 422 of FIG. 4Awith micro-texture. The third layer 430-3 includes shirrs 433, which areconfigured in the same way as the shirrs 432 of the second layer 430-2.

FIG. 4F illustrates an enlarged end view of the activated laminate ofFIG. 4A with micro-texture. The activated laminate 422 includes a firstdistance 486-1, a second distance 486-2, a third distance 486-3, afourth distance 486-4, a fifth distance 486-5, a sixth distance 486-6,and a seventh distance 486-7, which are respectively the same asdistances 484-1, 484-2, 484-3, 484-4, 484-5, 484-6, and 484-7, orslightly less due to contraction of the activated laminate 422. Thefirst layer 430-1 includes a plurality of corrugations 434, wherein thefirst layer 430-1 rises up to each attachment line in the firstattachment lines 440 and drops down to each attachment line in thesecond attachment lines 450.

FIG. 5A illustrates a top view of an alternate embodiment of athree-layer laminate 522 of the present disclosure, after activation, ina flat state. The activated laminate 522 is the same as the activatedlaminate 422, with like numbered elements configured in the same way,except as described below. The second attachment lines 550 include afourth line 550-4, a fifth line 550-5, and a sixth line 550-6, which arepositioned the same as the first attachment lines 540.

FIG. 5B illustrates a side view of the activated laminate 522 of FIG.5A.

FIG. 5C illustrates an end view of the activated laminate of FIG. 5A.The fourth line 550-4 is aligned subjacent the first line 540-1, thefifth line 550-5 is aligned subjacent the second line 540-2, and thesixth line 550-6 is aligned subjacent the third line 540-3. The secondattachment lines 550 are spaced with distances 584-5, 584-6, 584-7, and584-8, which are the same as the distances 584-1, 584-2, 584-3, and584-4 for the first attachment lines 540, respectively.

The intermediate laminate, from which the activated laminate 522 isformed, and the activated laminate 522 in a contracted state are notillustrated, although, based on the other embodiments of the presentdisclosure, their structure and form will be understood by one ofordinary skill in the art.

FIG. 6A illustrates a top view of another alternate embodiment of athree-layer laminate 622 of the present disclosure, after activation, ina flat state. The activated laminate 622 is the same as the activatedlaminate 522, with like numbered elements configured in the same way,except as described below. The second attachment lines 650 arepositioned differently than the second attachment lines 640.

FIG. 6B illustrates a side view of the activated laminate 622 of FIG.6A.

FIG. 6C illustrates an end view of the activated laminate 622 of FIG.6A. The second attachment lines 650 are oriented orthogonal to thesecond attachment lines 550. Instead of being oriented in the primarydirection 670, the second attachment lines 650 are oriented in thesecondary direction 680.

The intermediate laminate, from which the activated laminate 622 isformed, and the activated laminate 622 in a contracted state are notillustrated, although, based on the other embodiments of the presentdisclosure, their structure and form will be understood by one ofordinary skill in the art.

FIG. 7A illustrates a top view of an alternate embodiment of a two-layerlaminate 722 of the present disclosure, after activation, in a flatstate. The activated laminate 722 is the same as the activated laminate322, with like numbered elements configured in the same way, except asdescribed below. The first attachment lines 740 are positioneddifferently than the first attachment lines 340. Instead of beingcontinuous straight lines, the first attachment lines 740 are groups ofparallel line segments. A first group 741 includes line segmentsoriented in a direction parallel with the primary direction 770. Asecond group 742 includes line segments oriented in a direction parallelwith the secondary direction 780. A third group 743 includes linesegments oriented in a direction parallel with the primary direction770. A fourth group 744 includes line segments oriented in a directionparallel with the secondary direction 780. In various embodiments, thisrepeating pattern can be shortened or lengthened, with an increased ordecreased number of such groups.

FIG. 7B illustrates a side view of the activated laminate 722 of FIG.7A.

FIG. 7C illustrates an end view of the activated laminate 722 of FIG.7A.

The intermediate laminate, from which the activated laminate 722 isformed, and the activated laminate 722 in a contracted state are notillustrated, although, based on the other embodiments of the presentdisclosure, their structure and form will be understood by one ofordinary skill in the art.

FIGS. 8A-15B illustrate exemplary embodiments of attachment lines thatcan be used as first attachment lines and/or as second attachment lineswith any embodiment of the present disclosure. Throughout FIGS. 8A-15B,elements correspond with like numbered elements in other figures, unlessotherwise stated. It is contemplated that any of the embodiments ofattachment lines in FIGS. 8A-15B can alternatively be configured in anorthogonal orientation with respect to a laminate (i.e. in the secondarydirection, instead of the primary direction), or at any angle, withrespect to the primary direction and the secondary direction of alaminate.

FIG. 8A illustrates a top view of an intermediate laminate 821 of thepresent disclosure, with curved first attachment lines 840, beforeactivation. The intermediate laminate 821 includes a second layer 830-2,a primary direction 870, and a secondary direction 880.

FIG. 8B illustrates a top view of an activated laminate 822 withmicro-texture, which is the intermediate laminate 821 of FIG. 8A, afteractivation. The activated laminate 822 includes a plurality of shirrs832 in the second layer 830-2, wherein the shirrs 832 are oriented inthe secondary direction 880.

FIG. 9A illustrates a top view of an intermediate laminate 921 of thepresent disclosure, with oscillating first attachment lines 940, beforeactivation. In various embodiments, the oscillating first attachmentlines 940 can be provided in the Omega™ pattern by the ITW of Glenview,Ill. The intermediate laminate 921 includes a second layer 930-2, aprimary direction 970, and a secondary direction 980.

FIG. 9B illustrates a top view of an activated laminate 922 withmicro-texture, which is the intermediate laminate 921 of FIG. 9A, afteractivation. The activated laminate 922 includes a plurality of shirrs932 in the second layer 930-2, wherein the shirrs 932 are oriented inthe secondary direction 980.

FIG. 10A illustrates a top view of an intermediate laminate 1021 of thepresent disclosure, with first attachment lines 1040 comprising a seriesof dashes, before activation. The intermediate laminate 1021 includes asecond layer 1030-2, a primary direction 1070, and a secondary direction1080.

FIG. 10B illustrates a top view of an activated laminate 1022 withmicro-texture, which is the intermediate laminate 1021 of FIG. 10A,after activation. The activated laminate 1022 includes a plurality ofshirrs 1032 in the second layer 1030-2, wherein the shirrs 1032 areoriented in the secondary direction 1080.

FIG. 11A illustrates a top view of an intermediate laminate 1121 of thepresent disclosure, with first attachment lines 1140 comprising a seriesof dots, before activation. The intermediate laminate 1121 includes asecond layer 1130-2, a primary direction 1170, and a secondary direction1180.

FIG. 11B illustrates a top view of an activated laminate 1122 withmicro-texture, which is the intermediate laminate 1121 of FIG. 11A,after activation. The activated laminate 1122 includes a plurality ofshirrs 1132 in the second layer 1130-2, wherein the shirrs 1132 areoriented in the secondary direction 1180.

FIG. 12A illustrates a top view of an intermediate laminate 1221 of thepresent disclosure, with first attachment lines 1240 having a singleopen spiral pattern, before activation. The intermediate laminate 1221includes a second layer 1230-2, a primary direction 1270, and asecondary direction 1280.

FIG. 12B illustrates a top view of an activated laminate 1222 withmicro-texture, which is the intermediate laminate 1221 of FIG. 12A,after activation. The activated laminate 1222 includes a plurality ofshirrs 1232 in the second layer 1230-2, wherein the shirrs 1232 areoriented in the secondary direction 1280.

FIG. 13A illustrates a top view of an intermediate laminate 1321 of thepresent disclosure, with first attachment lines 1340 having a singletight spiral pattern, before activation. The intermediate laminate 1321includes a second layer 1330-2, a primary direction 1370, and asecondary direction 1380.

FIG. 13B illustrates a top view of an activated laminate 1322 withmicro-texture, which is the intermediate laminate 1321 of FIG. 13A,after activation. The activated laminate 1322 includes a plurality ofshirrs 1332 in the second layer 1330-2, wherein the shirrs 1332 areoriented in the secondary direction 1380.

FIG. 14A illustrates a top view of an intermediate laminate 1421 of thepresent disclosure, with first attachment lines 1440 having a dual tightspiral pattern, before activation. The intermediate laminate 1421includes a second layer 1430-2, a primary direction 1470, and asecondary direction 1480.

FIG. 14B illustrates a top view of an activated laminate 1422 withmicro-texture, which is the intermediate laminate 1421 of FIG. 14A,after activation. The activated laminate 1422 includes a plurality ofshirrs 1432 in the second layer 1430-2, wherein the shirrs 1432 areoriented in the secondary direction 1480.

FIG. 15A illustrates a top view of an intermediate laminate 1521 of thepresent disclosure, with randomly oriented first attachment lines 1540having a dual tight spiral pattern, before activation. The intermediatelaminate 1521 includes a second layer 1530-2, a primary direction 1570,and a secondary direction 1580.

FIG. 15B illustrates a top view of an activated laminate 1522 withmicro-texture, which is the intermediate laminate 1521 of FIG. 15A,after activation. The activated laminate 1522 includes a plurality ofshirrs 1532 in the second layer 1530-2, wherein the shirrs 1532 areoriented in the secondary direction 1580.

FIG. 16A is a microscopic photograph of an outer edge of an activatedlaminate 1820 with micro-texture of the present disclosure. FIG. 16Ashows some close-up detail of shirrs 1832 on the laminate 1820. In FIG.16A, there are about five shirrs over a distance of about 1.8millimeters in a primary direction 1870, or about 28 shirrs percentimeter.

FIG. 16B is a microscopic photograph of a cross-section of an activatedlaminate 1820 with micro-texture of the present disclosure, cut in aprimary direction 1870 along an attachment line 1840-1. FIG. 16B showssome close-up detail of shirrs 1832-A on the laminate 1820, with theshirrs 1832-A filled with an adhesive along the attachment line 1840-1.

FIG. 17 is a graph illustrating number of shirrs per centimeter in aprimary direction versus attachment line spacing in millimeters forexemplary embodiments of an activated laminate with micro-texture of thepresent disclosure. Without wishing to be bound by this theory, thegraph of FIG. 17 appears to illustrate that the number of shirrs percentimeter is a function of attachment line spacing, with closely spacedattachment lines yielding a higher number of shirrs per distance andfarther spaced attachment lines yielding a lower number of shirrs perdistance. As a result, it appears that, for laminates of the presentdisclosure, the number of shirrs per centimeter can be controlled, atleast in part, by selecting a particular spacing for attachment lines.In FIG. 17, the data points represented by squares correspond with thelaminate of FIGS. 3A-3G, with the first layer being a sheet of filmhaving elastic properties and the second layer 330-2 being a nonwovenlaminated to a film having plastic properties, with attachment linespacings of 2 mm, 4 mm, 8 mm, 16 mm, and 25 mm. In FIG. 17, the datapoints represented by circles correspond with a variation of thelaminate of FIGS. 3A-3G, with the first layer being a sheet of filmhaving elastic properties and the second layer 330-2 being a nonwovenlaminated to a film having plastic properties, with attachment linespacings of 3 mm, 5 mm, 7.5 mm, 15 mm, and 25 mm. The scale of FIG. 19can be used to graphically determine exact values for the data points.The data shown in FIG. 19 was obtained by the Measurement Method UsingMicro Computer Tomography, described herein.

FIG. 18 is a graph illustrating shirr height in millimeters versusattachment line spacing in millimeters for exemplary embodiments of anactivated laminate with micro-texture of the present disclosure. Thegraph of FIG. 18 illustrates the fact that shirr height is likely afunction of attachment line spacing, with closely spaced attachmentlines yielding a shorter shirrs and farther spaced attachment linesyielding taller shirrs. In FIG. 18, the data points represented bysquares correspond with the laminate of FIGS. 3A-3G, with the firstlayer being a sheet of film having elastic properties and the secondlayer 330-2 being a nonwoven laminated to a film having plasticproperties, with attachment line spacings of 2 mm, 4 mm, 8 mm, 16 mm,and 25 mm. In FIG. 18, the data points represented by circles correspondwith a variation of the laminate of FIGS. 3A-3G, with the first layerbeing a sheet of film having elastic properties and the second layer330-2 being a nonwoven laminated to a film having plastic properties,with attachment line spacings of 3 mm, 5 mm, 7.5 mm, 15 mm, and 25 mm.The scale of FIG. 18 can be used to graphically determine exact valuesfor the data points. The data shown in FIG. 18 was obtained by theMeasurement Method Using Micro Computer Tomography, described herein.

Hysteresis Test

The Hysteresis Test utilizes a commercial tensile tester (e.g., fromInstron Engineering Corp. (Canton, Mass.), SINTECH-MTS SystemsCorporation (Eden Prairie, Minn.) or equivalent) interfaced with acomputer. The computer is used to control the test speed and other testparameters and for collecting, calculating, and reporting the data. Thetests are performed under laboratory conditions of 23° C.±2° C. andrelative humidity of 50%±2%. The samples are conditioned for 24 hoursprior to testing.

Test Protocol

1. Select the appropriate jaws and load cell. The jaws must have flatsurfaces and must be wide enough to fit the sample (e.g., at least 2.54cm wide). Also, the jaws should provide adequate force to ensure thatthe sample does not slip during testing. The load cell is selected sothat the tensile response from the sample tested is between 25% and 75%of the capacity of the load cell used.

2. Calibrate the tester according to the manufacturer's instructions.

3. Set the distance between the grips (gauge length) to 25.4 mm.

4. Place the sample in the flat surface of the jaws such that thedirection of interest is parallel to the gauge length direction. Mountthe sample in the upper grip, let the sample hang slack, then close thelower grip. Set the slack preload at 0.02 N/cm. This means that the datacollection starts when the slack is removed (at a constant crossheadspeed of 10 mm/min) with a force of 0.02 N/cm. Strain is calculatedbased on the adjusted gauge length (l_(ini)), which is the length of thesample in between the grips of the tensile tester at a force of 0.02N/cm. This adjusted gauge length is taken as the initial sample length,and it corresponds to a strain of 0%. Percent strain at any point in thetest is defined as the change in length divided by the adjusted gaugelength times 100.

5(a). First cycle loading: Pull the sample to 200% strain at a constantcross head speed of 100 mm/min. Report the stretched sample lengthbetween the jaws as l_(max).

5(b). First cycle unloading: Hold the sample at 200% strain for 30seconds and then return the crosshead to its starting position (0%strain or initial sample length, lini) at a constant cross head speed of100 mm/min. Hold the sample in the unstrained state for 60 seconds.

5(c). Second cycle loading: Pull the sample to 200% strain at a constantcross head speed of 100 mm/min.

5(d). Second cycle unload: Hold the sample at 200% strain for 30 secondsand then return the crosshead to its starting position (i.e. 0% strain)at a constant cross head speed of 100 mm/min.

A computer data system records the force exerted on the sample duringthe test as a function of applied strain. From the resulting datagenerated, the following quantities are reported (note that loads arereported as force divided by the width of the sample and do not takeinto account the thickness of the sample):

1. Length of sample between the grips at a slack preload of 0.02 N/cm(l_(ini)) to the nearest 0.001 mm.

2. Length of sample between the grips on first cycle at the specifiedstrain (l_(max)) to the nearest 0.001 mm.

3. Length of sample between the grips at a second cycle load force of0.02 N/cm (l_(ext)) to the nearest 0.001 mm.

4. % set, which is defined as (l_(ext)−l_(ini))/(l_(max)−l_(ini))*100%to the nearest 0.01%.

The testing is repeated for six separate samples and the average andstandard deviation reported.

Dimension Method

Various dimensions and ratios thereof are specified herein. Unlessotherwise stated, each dimension is measured according to the followingmethod. All testing is performed in a conditioned room maintained atabout 23 C±2 C and about 50%±2% relative humidity. Herein, width andlength of the specimen are a lateral width and longitudinal length asdefined herein. Precondition specimens at about 23 C±2 C and about50%±2% relative humidity for 2 hours prior to testing.

Prepare the article for testing as follows:

1. Lay the article on a substantially flat, horizontal surface.

2. Secure the article to the surface such that all process-inducedcontraction acting to forshorten the absorbent core assembly is pulledout. For example, a pre-contracted waistband applied to the article orelastics along the longitudinal edges of the article and/or theabsorbent core assembled may forshorten the article laterally orrespectively longitudinally, so any such process-induced contraction ispulled out. The article is secured to the flat, horizontal surface withclamps or adhesive tape capable of holding the absorbent core assemblywith process-induced contraction pulled out.

3. Identify points between which widths and/or lengths of eachattachment region, the absorbent core assembly, any unattached areas,and the article are to be measured, per definitions contained herein.This includes defining the hip region.

4. Measure each needed dimension to the nearest 1 mm using a steel rulertraceable to NIST.

5. Calculate any needed ratios as follows: Ratio=100%×[FirstMeasurement/Second Measurement].

Measurement Method Using Micro Computer Tomography

Micro computer tomography can be used, as described below, to measurethe number of shirrs per centimeter and the shirr height in activatedlaminates of the present disclosure. This method is only intended formeasuring a mechanically activated laminate between two parallel andlinear lines of attachment that attach a first to a second layer, asdescribed herein. This method can be used for laminates such as these,that also include additional layers.

First, cut a round sample of the laminate material to be tested, witheach sample approximately 36 mm in diameter.

Second, position the sample obtained from step one for scanning withfirst layer on the bottom, facing downward, and the second layer on thetop, facing upward. For stable positioning, the bottom of the sample canbe adhesively mounted onto a positioning surface, using double-sidedadhesive foam. The sample should be undeformed, with the top and thesides of the sample left open to the air and unobstructed. Once mounted,the sample should lie substantially flat without significant wrinkles.If the sample does not lie flat, then shim material may be added underportions of the sample, for extra support. If the sample still does notlie flat, then it may be turned over so the second layer is on thebottom and the first layer is on the top.

Third, scan the positioned sample from step two with a micro-computertomography system, such as μCT 40, ID#4286, serial #07030700, availablefrom Scanco Medical AG of Wayne, Pa., USA. For this system, use thefollowing scanning parameters: high resolution (1000 projections per 180degrees) x-ray tube set for a current of 110-180 μA and a peak energy of35 kVp, 300 millisecond integration time, and a frame averaging of 10.Scan with a slice increment of 18 μm. For samples of the size describedherein, this may require a scanning time of several hours. For othersystems, use equivalent settings.

Fourth, process the scan data from step three. Use each slice(consisting of 1000 projections) to reconstruct the image in a 2048×2048pixel matrix, with a pixel resolution of 18 μm. Import the scan datainto visualization software. For example, for reconstructed data fromthe Scanco Medical machine (described above), convert the data into an.AVW file and import the data into Avizo visualization software(versions 6.0 or higher, offered by Visualization Sciences Group) usinga MATLAB script.

Fifth, align the scanned image data of the laminate from step four witheach axis in the visualization space. This may require manual rotation,as follows. For the Z-axis, look at the XY plane of an orthoslice androtate the data/image in small increments around the Z-axis until thelines of attachment in the laminate align with the Y-axis at the edge ofthe viewing area. As an example, in Avizo, apply the rotationtransformation to all voxels using the standard Apply Transform commandCheck the results by taking a YZ orthoslice of the rotated data/image,viewing it as a straight line from the XY perspective, and checking foralignment with a line of attachment. If the orthoslice is closelyaligned with the attachment line, then the rotation is complete. If not,then repeat the manual rotation step to improve the alignment. Repeatthis procedure for the X and Y axes. At the end of the rotation step,the secondary direction of the laminate should coincide with the X axis,the primary direction of the laminate should coincide with the Y axis,and the tertiary direction of the laminate should coincide with the Zaxis. As a result, the lines of attachment should line in the XY planeand should be oriented in the Y direction.

Sixth, use the rotated scan data from step five to make measurements ofthe laminate in the visualization software.

Define a rectangular volume of interest for the measurement. The top ofthe volume is in an XY plane and is defined by the outermost extent ofthe top of the shirrs of the second layer (disposed away from the firstlayer). The bottom of the volume defined is in an XY plane and isdefined by the innermost extent of the bottom of the shirrs of thesecond layer (disposed toward the first layer). The left and right sidesof the volume are each in a YZ plane and are defined by aligning the twosides on two adjacent lines of attachment in the laminate. The front andback sides of the volume are each in an XZ plane and are defined by thearea of interest between the lines of attachment and in the Y axisdirection.

Next, create an image for counting shirr crossings. Define a slicingplane within the volume of interest. The slicing plane is an XY plane,parallel to and midway between the top and the bottom of the volume.Take an orthoslice of the scan data at the slicing plane to create animage of the cross-sections of the shirrs of the second layer. In theimage, the cross-sections of the shirrs appear wherever the shirrs crossthe slicing plane. Define a reference line within the slicing plane. Thereference line is oriented in the Y direction, parallel to the lines ofattachment. Determine the overall length of the reference line incentimeters, from the front of the volume to the back of the volume.Make the reference line visible within the image of the cross-sections.

Next, determine the number of shirrs per centimeter. Using the imagecreated from the slicing plane, manually count the number ofintersections between shirr crossings and the reference line, along thereference line. Since there are two intersections for each shirr, dividethe number of intersections along the reference line by two to obtainthe number of shirrs along the reference line. Divide the number ofshirrs along the reference line by the overall length of the referenceline to obtain the number of shirrs per centimeter.

Next, determine the shirr height. In the Z direction, measure theoverall distance between the top and the bottom of the volume ofinterest.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm.”

Every document cited herein, including any cross referenced or relatedpatent or application, is hereby incorporated herein by reference in itsentirety unless expressly excluded or otherwise limited. The citation ofany document is not an admission that it is prior art with respect toany invention disclosed or claimed herein or that it alone, or in anycombination with any other reference or references, teaches, suggests ordiscloses any such invention. Further, to the extent that any meaning ordefinition of a term in this document conflicts with any meaning ordefinition of the same term in a document incorporated by reference, themeaning or definition assigned to that term in this document shallgovern.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

What is claimed is:
 1. A laminate, comprising: a primary direction; asecondary direction that is perpendicular to the primary direction; afirst layer having, in the primary direction, a first extensibility anda first elasticity with a first set; a second layer having, in theprimary direction, a second extensibility and a second elasticity with asecond set that is greater than the first set; a first attachment line;wherein the first layer is attached to the second layer only by a firstattachment area, and wherein the first attachment area is primarilyformed by the first attachment line; and wherein the laminate has, inthe primary direction, a laminate extensibility and a laminateelasticity with a laminate set; a plurality of shirrs in the secondlayer, wherein each of the shirrs is substantially parallel with thesecondary direction; and a plurality of corrugations in the first layer,wherein each of the corrugations is substantially parallel with theprimary direction.
 2. The laminate of claim 1, wherein: the firstattachment line is included in a plurality of first attachments lines,wherein each of the first attachment lines is oriented in a direction oforientation that is substantially parallel with the primary direction;and the first attachment area is primarily formed by the firstattachment lines.
 3. The laminate of claim 2, wherein each of the firstattachment lines is a substantially continuous line.
 4. The laminate ofclaim 2, wherein each of the first attachment lines is a line ofadhesive.
 5. The laminate of claim 2, wherein the plurality of firstattachment lines has at least three lines.
 6. The laminate of claim 2,wherein the plurality of first attachment lines has a uniform spacing.7. The laminate of claim 2, wherein adjacent lines in the plurality offirst attachment lines are spaced apart by a distance that is greaterthan or equal to two millimeters.
 8. The laminate of claim 2, whereineach of the first attachment lines has a line width less than or equalto one millimeter.
 9. The laminate of claim 1, wherein the laminate isin the form of a band with an overall length in a longitudinal directionand an overall width in a lateral direction, and wherein the overalllength is substantially greater than the overall width.
 10. The laminateof claim 9, wherein the primary direction is parallel with thelongitudinal direction.
 11. The laminate of claim 1, wherein the firstlayer is a film.
 12. The laminate of claim 1, wherein the first set isless than or equal to 20% when measured using a Hysteresis Test.
 13. Thelaminate of claim 1, wherein the second layer is a laminate formed by afilm and nonwoven.
 14. The laminate of claim 1, wherein the second setis greater than or equal to 50% when measured using a Hysteresis Test.15. The laminate of claim 1, wherein substantially all of the firstattachment area is formed by the first attachment line.
 16. The laminateof claim 1, wherein the first layer is attached to the second layer byan attachment with an overall peel strength and substantially all of theoverall peel strength is provided by the first attachment line.
 17. Thelaminate of claim 1, wherein the laminate extensibility is greater thanor equal to 50%.
 18. The laminate of claim 1, wherein the laminate is inthe form of a band with an overall length in a longitudinal directionand an overall width in a lateral direction, wherein the overall lengthis substantially greater than the overall width, and wherein the overallwidth is less than or equal to 20 millimeters.
 19. The laminate of claim1, wherein the second layer has been incrementally stretched in theprimary direction.
 20. The laminate of claim 19, wherein the shirrs arespaced such that there are at least eight shirrs per centimeter.
 21. Thelaminate of claim 19, wherein each of the shirrs has an overall heightthat is less than or about equal to 2.0 millimeters.
 22. The laminate ofclaim 19, wherein each of the corrugations has an overall height that isgreater than or equal to 1.0 millimeter.
 23. A disposable wearableabsorbent article, comprising the laminate of claim
 1. 24. The articleof claim 23, comprising a front waistband formed by the laminate. 25.The article of claim 24, comprising a rear waistband formed by thelaminate.
 26. The laminate of claim 1, wherein: a third layer having, inthe primary direction, a third extensibility and a third elasticity witha third set that is greater than the first set; and a second attachmentline; wherein the first layer is attached to the third layer only by asecond attachment area, and the second attachment area is primarilyformed by the second attachment line.
 27. The laminate of claim 26,wherein the third layer is a film.
 28. The laminate of claim 26, whereinthe third layer is a nonwoven.
 29. The laminate of claim 1, wherein thefirst and second layers are incrementally stretched in the primarydirection.
 30. A method of making a laminate, the method comprising:providing a first layer having, in a primary direction, a firstextensibility and a first elasticity with a first set; providing asecond layer having, in the primary direction, a second extensibilityand a second elasticity with a second set that is greater than the firstset; attaching the first layer to the second layer by a first attachmentarea, primarily formed by a first attachment line to form anintermediate laminate; forming a plurality of corrugations in the firstlayer in a direction substantially parallel with the primary direction;forming a plurality of shirrs in the second layer in a directionsubstantially parallel with the secondary direction; and incrementallystretching the intermediate laminate in the primary direction to formthe plurality of corrugations and the plurality of shirrs.
 31. Themethod of claim 30, wherein the attaching comprises attaching the firstlayer to the second layer by a plurality of first attachments lines,wherein each of the first attachment lines is oriented in a direction oforientation that is substantially parallel with the primary direction,and wherein the first attachment area is primarily formed by the firstattachment lines.
 32. The method of claim 31, wherein the attachingcomprises attaching the first layer to the second layer by the pluralityof first attachments lines, and wherein each of the first attachmentlines is a line of adhesive.
 33. The method of claim 30, comprisingincrementally stretching the intermediate laminate by mechanicallyactivating the intermediate laminate in the primary direction to formthe laminate.
 34. The method of claim 30, comprising: providing a thirdlayer having, in the primary direction, a third extensibility and athird elasticity with a third set that is greater than the first set;and attaching the first layer to the third layer by a second attachmentarea, primarily formed by a second attachment line to form theintermediate laminate.
 35. A laminate, comprising: a primary direction;a secondary direction that is perpendicular to the primary direction; afirst layer having, in the primary direction, a first extensibility anda first elasticity with a first set; a second layer having, in theprimary direction, a second extensibility and a second elasticity with asecond set that is greater than the first set; a first attachment lineformed by a line of adhesive; wherein the first layer is attached to thesecond layer only by a first attachment area, and the first attachmentarea is primarily formed by the first attachment line; and wherein thelaminate has, in the primary direction, a laminate extensibility and alaminate elasticity with a laminate set; a plurality of shirrs in thesecond layer, wherein each of the shirrs is substantially parallel withthe secondary direction; and a plurality of corrugations in the firstlayer, wherein each of the corrugations is substantially parallel withthe primary direction; wherein the first and second layers areincrementally stretched in the primary direction.
 36. The laminate ofclaim 35, wherein the first and second layers comprise a film.
 37. Adisposable wearable absorbent article, comprising the laminate of claim35.
 38. The article of claim 37, comprising a front waistband formed bythe laminate.
 39. The article of claim 37, comprising a rear waistbandformed by the laminate.